Mold for creating negative draft surfaces in molded items and method of molding

ABSTRACT

A one-piece mold can be used to form molded items that incorporate features or encroachments with negative draft angles, and such molded items can be removed from the mold in a single piece by lifting, tilting, or pulling, or a combination thereof, without breaking the mold or the item to be molded. The mold and method of molding are suited to a bathtub or shower unit. The mold and method of molding permit the removal of molded items with negative draft angles by coordinating the angle of the sump front wall and sump back wall with the angles of other encroachments in the molded item within specified ranges that permit one-piece removal of the item to be molded from the mold.

CROSS-REFERENCES TO RELATED APPLICATIONS

None

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

BACKGROUND

The present invention relates to a one-piece mold for forming a bathingunit that comprises as a single piece a bathtub and bathtub surround ora single-piece shower and shower surround, with such mold formingencroachments within the bathing unit that incorporate negative draftangles. The present invention further relates to a method of moldingsuch a bathing unit.

Molded bathing units that comprise as a single piece a bathtub andbathtub surround or shower and shower surround are preferable to bathingunits molded or formed from two or more separate pieces. Bathing unitsmolded as a single piece are typically more economical to produce andoften have superior structural and design characteristics for certainapplications. Specifically, such bathing units are ideal for use inspace-limited areas, such as the bathroom of a recreational vehicle.

Typically, one-piece molds for bathing units are configured so thatencroachments molded into the bathing unit incorporate positive draftangles. It has long been believed in the art that avoiding negativedraft angles in the mold and item to be molded is necessary to permitthe molded item to be removed from the mold without breaking the moldeditem or the mold. Using molds and methods of molding known in the art,forming an encroachment with a negative draft angle in a molded itemwould require either the use of a two-piece mold, or the breaking orcutting of the molded item to enable removal of the item from the mold.

The inability of one-piece molds and methods of molding known to the artto accommodate encroachments with negative draft angles significantlylimits the design features possible for bathing units formed by suchmolds and methods of molding. To avoid negative draft angles, molds andmethods of molding known to the art form each encroachment in a bathingunit as a “pillar” running at a positive draft angle from the floor ofthe bathing unit to the height desired for the feature. Seats, benches,shelves, soap dishes, sump walls, and other encroachments within abathing unit are typically formed by the upper face of such “pillars,”as shown in FIG. 2. This configuration permits removal of the bathingunit from the mold. However, the necessity of forming a pillar extendingto the floor of the bathing unit to accompany each desired encroachmentreduces the space available to the user within the unit, andspecifically reduces floorspace available to the user.

As a result, molds and methods of molding known to the art typicallylimit the number and size of encroachments—and thus, the number and sizeof features such as seats, shelves, benches, and dishes within suchbathing units—to preserve space and floorspace within the unit. Further,molds and methods of molding known to the art cannot easily incorporateencroachments directly above or directly below other encroachmentsbecause of the difficulty of forming a positive draft angle for all butthe lowermost encroachment. This significantly limits the designpossibilities of bathing units formed by molds and methods of moldingknown to the art.

Accordingly, it is desirable to provide a one-piece mold and method ofmolding using a one-piece mold that is capable of producing an item,with encroachments that incorporate negative draft angles, that can beremoved from the mold in a single piece without breaking the mold or theitem. Preferably, such item is a bathing unit.

SUMMARY OF THE INVENTION

These and other objects are achieved by the present invention, whichprovides a one-piece mold capable of forming a bathing unit thatcomprises, as a single piece, a bathtub and tub surround or shower andshower surround, with encroachments within the unit that incorporatenegative draft angles, that can be removed from the mold in a singlepiece without breaking the mold or the bathing unit. The presentinvention further provides a method of molding the same.

A mold according to versions of the present invention is can be madefrom any of a wide range of materials known to those skilled in therelevant art. The mold can be made substantially from a nonstickmaterial, can be coated with such a material, or, alternately, the moldor item to be molded can be treated with a release agent appropriate toallow the material to be molded to be removed from the mold afterhardening.

The mold is configured to form an item to be molded as a rigid shell ina desired shape, which shape includes desired encroachments formed bythe contours of the mold. Preferably, the item to be molded is a bathingunit, and such encroachments comprise features such as shelves, seats,benches, sump walls, or dishes. The mold is configured to form sumpwalls and encroachments with draft angles coordinated within specifiedranges such that the item to be molded can be removed from the mold bypulling, tilting, or lifting, or some combination thereof, withoutbreaking the mold or the item to be molded.

A method of molding according to versions of the present inventionemploys a single-piece mold as described herein. The material intendedto form the item to be molded is applied to the mold by pouring,spraying, painting, rolling, or other means of application. The materialis allowed to dry, cure, or otherwise hardens. After the materialhardens substantially, the item is removed from the mold by pulling,tilting, lifting, or some combination thereof. Due to the coordinationof angles of the sump walls and encroachments formed by the mold, themolded item can be removed in a single piece from the mold by pulling,tilting, or lifting, or some combination thereof, without breaking themold or the item to be molded.

For a more complete description of the present invention, reference ismade to the following description, figures, and claims. It will beappreciated by one skilled in the art that the mold and method ofmolding of this invention are not limited to specific items to bemolded, to specific materials from which the mold is formed, or tospecific materials from which the item is formed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a mold according to a version of thepresent invention.

FIG. 2 is a front view of a bathing unit formed according to a mold andmethod of molding known to the art and incorporating only encroachmentswith positive draft angles.

FIG. 3 is a front view of a bathtub unit formed according to a mold andmethod of molding of the present invention, incorporating encroachmentswith negative draft angles.

FIG. 4 is a front view of a shower unit formed according to a mold andmethod of molding of the present invention, incorporating encroachmentswith negative draft angles.

FIG. 5 is an enlarged view of an encroachment incorporating a negativedraft angle formed according to the teachings of the present invention.

FIG. 6 is an enlarged view of a portion of a mold according to teachingsof the present invention configured to form a negative draftencroachment.

FIG. 7 is a side view of a mold according to the prior art.

DESCRIPTION OF THE INVENTION

A mold [1] according to versions of the present invention is shown inFIG. 1. The mold [1] is a single-piece mold that is formed from any of awide range of materials known to those skilled in the relevant art. Themold [1] can be made substantially from a nonstick material, can becoated with such a material, or, alternately, the mold [1] or item to bemolded can be treated with a release agent appropriate to allow thematerial to be molded to be removed from the mold [1] after hardening.

A mold [1] according to versions of the present invention is comprisedof a base [3] and walls [5] connected to said base [3]. The base [3] andwalls [5] of the mold [1] are configured so that when material to bemolded is applied to the mold [1], then substantially hardens, and isthen removed from the mold [1] in the general direction of the base [3]of the mold, also known as the direction of pull, the finish side of themolded item will comprise substantially the shape determined by thecontours of the mold [1]. Preferably, the base [3] and walls [5] of themold are configured so that when material to be molded is applied to themold, substantially hardens, and is removed from the mold, a bathingunit that includes encroachments [7] is formed. Preferably, the bathingunit so formed will be a single piece comprising a bathtub and bathtubsurround, or a single piece comprising a shower and shower surround, andat least some of the encroachments [7] therein will incorporate negativedraft angles according to the teachings of the present invention.“Bathing unit,” as that term is used herein, comprises both bathtub andshower units.

The item formed by the mold [1] and method of molding according toversions of the present invention is formed as a substantially rigidshell with a finish side [9] and a non-finish side [11]. The finish side[9] of the molded item is the face of the item that, during theapplication and hardening phase of the molding process, remainssubstantially in contact with the mold [1]. The non-finish side [11] ofthe molded item is the face of the molded item that, during thehardening phase of the molding process, is facing substantially outwardfrom the surface of the mold [11].

Preferably, the item to be molded is a bathing unit. As shown in FIGS. 3and 4, the finish side [9] of the bathing unit formed according to theteachings of the present invention comprises interior faces of thebathing unit that would be visible to a user during use of the bathingunit. Such faces, by way of illustration, comprise a floor [13], a sump[15] in which a user would stand or bathe, a sump front wall [17], asump back wall [19], a unit back wall [21], and, optionally, unit sidewalls [23].

The non-finish side [11] of the bathing unit comprises the exteriorfaces of the unit. The non-finish side [11] of a bathing unit would nottypically be visible to a user using the bathing unit, as suchnon-finish side [11] is typically concealed by framing, plumbing, orother structures.

The finish side [9] of a molded item will be referred to as the “inward”surface of the item, and the non-finish side [11] will be referred to asthe “outward” surface thereof. The direction of the item formed by thebase [3] of the mold [1] will be referred to as “downward,” and thedirection opposite the base [3] of the mold [1] will be referred to as“upward.”

The item to be molded according to versions of the present invention canbe made of any material suitable for molding on or in a one-piece mold[1]. Preferably, such materials will be selected such that when thematerial has hardened, it will have structural properties suitable forthe intended use of the item. Suitable materials include those that canbe formed, converted, suspended, or included in fluid matter appropriatefor application to a mold [1], such as liquids, foams, gels, or sprays,and then, after application, can be dried, cured, or hardened such thatthe material forms a shell that can be removed from the mold [1]. Suchdrying, curing, or hardening process will be referred to as “hardening.”

It will be recognized by those skilled in the art that the moldingprocess may involve chemical or physical changes to the material beingmolded with or without dehydration and with or without the applicationof heat. Appropriate materials include fiberglass, thermoplastics, andother polymers. Other materials appropriate for use will be apparent toone skilled in the art.

A mold [1] according to versions of the present invention is configuredto form encroachments [7] in the item to be molded. “Encroachments” asused herein means any fixture, feature, or design element that is formedby the shape or contour of the mold [1]. Preferably, encroachments [7]comprise features desirable in bathing units such as seats, benches,ledges, shelves, dishes, and sump walls. It will be appreciated thatother encroachments [7] are within the scope of the teachings of thepresent invention.

A mold [1] according to versions of the present invention utilizesvariations in the shape or contour of the mold walls [5] or mold base[3] to form encroachments [7] in a molded item. By way of illustration,a depression in the wall [5] of a mold [1] may be used to form anencroachment [7] in the item to be molded. FIG. 6 demonstrates a portionof a mold configured to form a negative draft angle encroachment in amolded bathing unit.

Versions of the present invention can form molded items incorporatingencroachments [7] with negative draft angles that can be removed fromthe mold [1] without breaking the mold [1] or the molded item. FIGS. 3and 4 show a bathtub unit and shower unit, respectively, formedaccording to the teachings of a version of the invention herein.

“Positive draft” and “negative draft” angles of are defined in terms ofthe mold surface and the direction of pull for removal of items formedon the mold. In the case of a mold for a bathing unit, for example, thewall [5] of the mold [1] that forms the unit back wall [21] is typicallythe upper surface of the mold, and the direction of pull is in thedirection of the base [3]. “Positive draft” angles are those angles thatcreate a surface that slopes away in the direction of pull from atheoretical horizontal axis lying atop the outermost portion of saidmold back wall, such that portions of the angled surface located furthertowards the direction of pull are more distant from said horizontal axisthan portions of said angled surface located further opposite thedirection of pull. “Negative draft” angles are those angles that createa surface that slopes away opposite the direction of pull from atheoretical horizontal axis lying atop the outermost portion of saidmold back wall, such that portions of the angled surface more removedfrom the direction of pull are more distant from said horizontal axisthan portions of the angled surface further towards the direction ofpull. The magnitude of the angle of draft is measured with reference tosaid theoretical hypothetical axis.

The negative draft angle of encroachments [7] formed by the mold andmethod of molding of the versions of the invention herein permitencroachments [7] to be incorporated in the molded item without the needfor forming a pillar running downwardly from each encroachment [7], asis typically required by positive draft encroachments. FIG. 5 shows anenlarged view of a bench encroachment incorporating a negative draftangle according to the teachings of the present invention.

Preferably, as used in connection with a bathing unit, the teachings ofversions of the present invention permit seats or benches to incorporatea negative draft angle, resulting in a reduction in the amount offloorspace occupied thereby. Versions of the present invention furtherpermit shelves, dishes, and sump front walls [17] to incorporate anegative draft angle, resulting in an increase in the space andfloorspace available in the portions of the bathing unit under theencroachment [7]. Versions of the present invention further permitmultiple encroachments to be positioned vertically above or beneath eachother without reducing the amount of space or floorspace available underthe lowermost encroachment.

The teachings of the present invention include configuring a mold [1]for a bathing unit so as to coordinate within specified ranges the draftangles of the sump front wall [17] and sump back wall [19] with thedraft angles of other encroachments [7] within the unit. The range ofdraft angles permitted for any particular encroachment [7] is a functionof the depth of the sump [15] and the distance of the encroachment [7]from the floor [13] of the unit. Configuring a mold [1] to formencroachments [7] incorporating draft angles within appropriate rangesfor particular sump [15] depths and particular heights of encroachment[7] permits the bathing unit to be removed from the mold [1] in a singlepiece without breaking the mold [1] or the bathing unit, according tothe teachings of this invention.

A mold [1] according to a preferred bathing unit embodiment of thisinvention is divided into three zones: a sump zone [25], a middle zone[27], and an upper zone [29]. The sump zone [25] is that part of themold [1] that forms the portion of the bathing unit extending from thefloor [13] of the unit upwards to approximately top of the sump frontwall [17]. The middle zone [27] is that part of the mold [1] forming theportion of the item to be molded extending from the top of the sump zone[25] to approximately one half of the distance between the top of thesump zone [25] and the proximal end of the bathing unit furthest fromthe floor [13]. The upper zone [29] is that part of the mold [1] formingthe portion of the item to be molded extending from the top of themiddle zone [27] to the proximal end of the bathing unit furthest fromthe floor [13]. It will be appreciated that the size of each zone withrespect to the other zones will vary as a function of the overall heightof the unit and the dimensions of the sump [15]. It will further beappreciated that the teachings of this invention can be accomplishedwith use of more or fewer zones than specified in the embodimentsdescribed herein.

As related to a preferred embodiment of a bathtub unit as shown in FIG.3, the configuration of a mold [1] according to versions of the presentinvention is as follows:

The portion of the mold [1] that forms the sump front wall [17] isconfigured to form a negative draft angle of approximately 10 degrees,and the portion of the mold [1] that forms the sump back wall [19] isconfigured to form a negative draft angle of a magnitude not greaterthan the magnitude of the angle of the sump front wall, preferably notexceeding 8 degrees;

Portions of the mold [1] that form encroachments [7] in the sump zone[25] other than the sump back wall [19] are configured to form suchencroachments [7] with a negative draft angle with a magnitude of anglenot exceeding the magnitude of angle of the sump front wall [17], suchnegative draft angle preferably not exceeding approximately 8 degrees;

Portions of the mold [1] that form encroachments in the middle zone [27]are configured to form such encroachments [7] incorporating a negativedraft angle not exceeding approximately 40 degrees; and

Portions of the mold [1] that form encroachments [7] in the upper zone[29] are configured to form such encroachments [7] incorporating anegative draft angle not exceeding approximately 45 degrees.

As related to a preferred embodiment of a shower unit, as shown in FIG.4, the configuration of a mold [1] according to versions of the presentinvention is as follows:

The portion of the mold [1] that forms the sump front wall [17] isconfigured to form a negative draft angle of approximately 30 degrees,and the portion of the mold [1] that forms the sump back wall [19] isconfigured to form a negative draft angle of a magnitude not greaterthan the magnitude of the angle of the sump front wall, preferably notexceeding approximately 25 degrees;

Portions of the mold [1] that form encroachments [7] in the sump zone[25] other than the sump back wall [19] are configured to form suchencroachments [7] incorporating a negative draft angle with a magnitudeof angle not exceeding the magnitude of angle of the sump front wall[17], such negative draft angle preferably not exceeding approximately25 degrees;

Portions of the mold [1] that form encroachments [7] in the middle zone[27] are configured to form such encroachments [7] incorporating anegative draft angle not exceeding approximately 40 degrees; and

Portions of the mold [1] that form encroachments [7] in the upper zone[29] are configured to form such encroachments [7] incorporating anegative draft angle not exceeding approximately 45 degrees.

When a mold [1] is configured according to the teaching of versions ofthe present invention, it is possible for the molded item to be removedfrom the mold [1] in one piece, without breaking the mold [1] or themolded item. Removal of the molded item from the mold [1] may beaccomplished by pulling, tilting, or lifting the molded item from themold [1], or by any combination of pulling, tilting, or lifting themolded item from the mold [1].

A method of molding according to versions of the present invention usesa mold [1] as described herein and comprises the steps of substantiallycovering the molding surfaces of the mold [1] with the material to bemolded, allowing the material to be molded to dry, cure, or otherwiseharden sufficiently to permit the removal of such material from the mold[1], and removing the item formed by such material from the mold [1] bypulling, tilting, or lifting, or any combination of pulling, tilting, orlifting, without breaking the mold [1] or the item.

It will be appreciated by one skilled in the art that the scope of thepresent invention is not limited to the specific embodiments describedherein, and that other embodiments, materials, products, molded items,and encroachment types are within the scope of the present invention.

What is claimed is:
 1. A one-piece mold for a bathtub comprising a base,a rear wall, and at least one side wall, said mold forming a bathtubcomprising a sump, walls extending beyond said sump and one or moreadditional encroachments, wherein said sump comprises a sump front walland a sump back wall in which said mold forms said sump front wall toreflect a negative draft angle of approximately 10 degrees and formssaid sump back wall to reflect a negative draft angle of a magnitude notgreater than magnitude of the draft angle of said sump front wall, saidadditional encroachments comprise at least one of one or more shelvesand one or more seats, and at least one of said additional encroachmentsreflects a draft angle that is negative with respect to a direction ofpull parallel to the plane defined by said rear wall, such that saidbathtub can be removed from said mold through one or more of (a)pulling; (b) tilting; or (c) lifting without breaking said mold or saidbathtub formed by said mold.
 2. The mold of claim 1, in which portionsof the mold form said one or more additional encroachments in a sumpzone of said bathtub to reflect a negative draft angle of a magnitudenot exceeding 2 degrees less than the magnitude of angle of said sumpfront wall.
 3. The mold of claim 1, in which portions of the mold formsaid one or more additional encroachments in a middle zone of saidbathtub to reflect a negative draft angle not exceeding approximately 40degrees.
 4. The mold of claim 1, in which portions of the mold form saidone or more additional encroachments in an upper zone of said bathtub toreflect a negative draft angle not exceeding approximately 45 degrees.5. A one-piece mold for a shower comprising a base, a rear wall, and atleast one side wall, said mold forming a shower comprising a sump, wallsextending beyond said sump, and one or more additional encroachments,wherein said sump comprises a sump from wall and a sump back wall inwhich said mold forms said sump front wall to reflect a negative draftangle of approximately 30 degrees and forms said sump back wall toreflect a negative draft angle of a magnitude not greater than magnitudeof the draft angle of said sump front wall, said additionalencroachments comprise at least one of one or more shelves and one ormore seats, and at least one of said additional encroachments reflects adraft angle that is negative with respect to a direction of pullparallel to the plane defined by said rear wall, such that said showercan be removed from said mold through one or more of (a) pulling; (b)tilting; or (c) lifting without breaking said mold or said shower formedby said mold.
 6. The mold of claim 5, in which portions of mold formsaid one or more additional encroachments in a sump zone of said showerto reflect it negative draft angle of a magnitude not exceeding 5degrees less than the magnitude of angle of said sump front wall.
 7. Themold of claim 5, in which portions of the mold form said one or moreadditional encroachments in a middle zone of said shower to reflect asnegative draft angle not exceeding approximately 40 degrees.
 8. The moldof claim 5, in which portions of the mold form said one or moreadditional encroachments in an upper zone of said shower to reflect anegative draft angle not exceeding approximately 45 degrees.